1

NOVEMBER /// 2010

Large Format Lithium

Power Cells for

Demanding Hybrid

Applications

Adam J. Hunt

Manager of Government Programs

2011 Joint Service Power Expo

Power to Sustain Warfighter Dominance

Myrtle Beach, SC

May 4, 2011

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• Ener1 Overview • Negative Active Materials Comparison

• Lithium titanate vs. other common materials

• Lithium titanate characteristics • EnerDel LTO Cell Performance

• Small cells

• Large cells

• Multiple cells in series

• Conclusions & Final Remarks

CONTENTS

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GLOBAL SUPPLY STRATEGY

ENER1 / CORPORATE HQ / NYC, U.S.

ENER1 EUROPE / SALES & MARKETING / Paris, France

ENERDEL / Indianapolis, IN, U.S.

ENERDEL / Noblesville, IN, U.S.

ENERDEL / Mount Comfort, IN, U.S.

ENERDEL / R&D CENTER / Japan

ENER1 KOREA / Korea

WANXIANG / SHANGHAI, CHINA

THINK GLOBAL / Norway

Total Employees: 750 （Excl. China/Think)

Symbol/NASDAQ: HEV

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Easily replicated production processes allow us to expand capacity and locate facilities in-country near clients’ facilities

• Ener1 Lithium Group Established in 1990 • Delphi Lithium Group 1998 • EnerDel 2004 • Total Area: ~ 98,000 ft2

• Production & R&D of Lithium-Ion Cells for multiple applications

• Established in 2009 • Floor Space -38,500 ft2 • BMS Engineering & Test

U.S. FACILITIES

• Lease signed January 2010 • Total Area: 400,000 ft2 • Production Lithium-Ion Cells for

multiple applications • Final Pack Assembly Operations • Production Launch in May • Made possible by $118.5 million in

federal grant funding under the ARRA stimulus package

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EnerDel battery system concept provides maximum flexibility to meet

customer’s requirement

TOTAL SOLUTION PROVIDER FOR LI-ION

BATTERY SYSTEM

HEV System EV System

CELL • Advanced Prismatic Design

• High Performance Li-Ion Cells

SYSTEM

• High Speed Vehicle Communication

• Robust Battery System

• Integrated reuse design concept

MODULE

• Easy Maintenance Module Concept

• Integrated Thermal Management

• Voltage & Temperature Monitoring

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NEGATIVE ACTIVE MATERIAL COMPARISON

• Graphite – Most common active material for existing lithium ion cells

– Most energy density per volume

• Non-graphite carbon – Less reaction with electrolyte than graphite

– Higher power than graphite

– Longer life than graphite

• Lithium Titanate (Li4Ti5O12) – No reaction with electrolyte

– Less impedance

– Longer life

– Less Energy density

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NEGATIVE ACTIVE MATERIAL COMPARISON

Characteristic Graphite Carbon Lithium

Titanate

Long Life 3 2 1

Power 3 2 1

Energy 1 2 3

Low temperature 3 2 1

Safety 3 2 1

Lithium Titanate cell performance will be presented in this presentation

1 – BEST 2 – BETTER 3 - GOOD

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The Titanate Anode

• A very stable oxide best known for its safety and long cycle life • Theoretical capacity of 165 mAh/g is about half that of graphite (372 mAh/g) • It operates at 1.5V vs. Li which is above the voltage at which Li dendrites can occur • Less than 0.2% volumetric change from fully discharged Li4Ti5O12 to fully charged Li7Ti5O12 titanate (for comparison, graphite is 9% and silicon is 300%)

<J. Electrochem. Soc. 146(1999) 857>

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LTO CHARACTERISTICS

• Advantages

–Zero strain material • LTO ~ 0.02 % volume change

• Graphite ~ 9% volume change

–No lithium dendrites

– Less impedance than graphite

↓

High power

Good low temperature performance

Long life

Safety

• Disadvantages

– Lower Energy Density

– Lower Voltage Fig. XRD patterns of LTO material at different DOD

10 20 30 40 50 60 70 80

2 Theta / degree (CuKa)In

ten

sit

y /

Arb

. u

nit

DOD 0%

DOD 40%

DOD 90%

DOD 100%

(11

1)

(31

1) Cu

, (4

00

)

(31

1) C

u

(51

1)

(33

3)

(44

0)

(53

1) Cu

, (5

33

)

(62

2)

(44

4)

(22

2)

Li4Ti5O12 - spinel (LTO)

Li4Ti5O12 + xLi+ + xe- ↔ Li4+xTi5O12

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LTO Anode

Stan Whittingham SUNY

• The Li

insertion in

titanate occurs

at ~1.5V, well

above the

voltage at

which Li

deposition

occurs

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LTO negative shows less heat generation than graphite negative

THERMAL STABILITY OF LTO

Scan range; 50 – 350 oC Scan rate: 10 oC/min

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LTO HALF CELL RESULTS

• very flat charge or discharge curve

• very small irreversible capacity

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LTO HALF CELL RESULTS

• discharge rate capability is exceptional

• excellent for power applications (this is equivalent to discharge rate capability in a full cell)

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ENERDEL SMALL CELL DESIGN FOR LIGHT-DUTY VEHICLE APPLICATIONS

DESCRIPTION SPECIFICATION

Application Light-duty vehicle

Nominal Capacity 1.8Ah 5Ah

Max Voltage 2.8V

Min voltage 1.5V

Cell size 145 x 130 x 5 mm 200 x 111 x 5 mm

Chemistry LTO/LMO

15

25

30

35

40

45

50

55

60

65

70

0 10 20 30 40 50 60

Time / Min

Te

mp

era

ture

/ o

C1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

Vo

lta

ge

/ V

Cell Temperature

Voltage

25

30

35

40

45

50

55

60

65

70

0 10 20 30 40 50 60

Time / Min

Te

mp

era

ture

/ o

C

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

Vo

lta

ge

/ V

Cell Temperature

Voltage

TEMPERATURE INCREASE AT HIGH POWER CYCLE

LTO/LMO 1.8Ah Cell Graphite/LMO 1.8Ah Cell

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5 AH FULL CELL: HIGH TEMPERATURE CYCLING

• 2C cycling at 55°C

• excellent high temperature capacity retention

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0.0

0.2

0.4

0.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

0 500 1000 1500 2000 2500 3000

Cycle Number

Dis

ch

arg

e c

ap

acit

y /

Ah

CYCLE LIFE

• No capacity loss under severe cycling conditions.

55oC 5C charge 5C discharge 100% DOD

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EXTREME ABUSE TEST, LTO CELLS

-1.0

0.0

1.0

2.0

3.0

4.0

5.0

6.0

0 2 4 6 8 10 12 14 16 18

Time (min)

Vo

lta

ge

(V

)

0

30

60

90

120

150

180

210

Te

mp

era

ture

(C

)

Cell Voltage

Cell Temperature

Room Temperature

Nail penetrates

Overcharge and nail penetration

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HEV BATTERY PACK WITH ENERDEL LTO CELLS

We can reduce the battery size by one-half compared to existing Ni-MH pack

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LARGER SIZE LTO CELL

• Mixed oxide was used for the positive active materials instead of LMO

DESCRIPTION SPECIFICATION

Application Heavy-duty vehicle

Nominal Capacity 9.5Ah

Max Voltage 2.75V

Min voltage 1.6V

Cell size 172x 253 x 5.8 mm

Chemistry LTO/Mixed Oxide

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DISCHARGE PROFILE– 9.5AH CELL

1

1.2

1.4

1.6

1.8

2

2.2

2.4

0 2 4 6 8 10 12

Vo

ltag

e_V

Discharge capacity_Ah

1C

3C

5C

10C

20C

25C

0

0.5

1

1.5

2

2.5

3

0 2 4 6 8 10

Vo

lta

ge

(V)

Discharge_Capacity(Ah)

Cycle 3_30C

Cycle 803_26C

Discharge profile comparison at 3rd

cycle and 803rd cycle

Rate Capability

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CYCLE LIFE – 9.5AH CELL

Capacity loss is not observed through first 1000 cycles.

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THERMAL TEST WITH 3 CELLS IN SERIES (30°C)

8 points of the cell temperature were measured

Max 10oC increase with 25C continuous discharge

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3mm diameter nail, penetrating with a rate of 80 mm/s

NAIL PENETRATION (9.5AH CELL)

•No thermal event was observed. No explosion, no fire, no flame, no smoke. Irreversible cell damage. •EUCAR /SAE J2464 hazard level = 2 •Cell was not shorted right away. It took 1 hr for the cell voltage to reach 0V •Positive terminal temperature reached 32°C

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•SAFE

•LARGE FORMAT

•HIGH POWER

•LONG LIFE

•MECHANICALLY STABLE

•MADE IN THE UNITED STATES

•COMPATIBLE WITH EXISTING ENER1 MODULE STRUCTURE

CONCLUSIONS

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ACKNOWLEDGEMENT

Ener1 would like to thank the Department of Energy – National Energy Technology Laboratory for funding under cooperative research agreement

DE-FC26-08NT01929 and the U.S. Army Tank Automotive Research, Development and Engineering Center (TARDEC) for Financial Support in the

continued refinement and demonstration of the Titanate High-Power cells used for W56HZ-09-C-0681.

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THANKS FOR YOUR ATTENTION!

PLEASE VISIT US IN BOOTH #110

ADAM J. HUNT – MANAGER OF GOVERNMENT PROGRAMS

(317)585-3464

AHUNT@ENER1.COM

WWW.ENER1.COM